Methods and systems for coating and sealing inside piping systems

ABSTRACT

Methods and systems for cleaning, coating and sealing leaks in existing pipes, in a single operation. A piping system can be cleaned in one pass by dry particulates forced and pulled by air throughout the piping system by a generator and a vacuum. Pipes can be protected from water corrosion, erosion and electrolysis, extending the life of pipes such as copper, steel, lead, brass, cast iron piping and composite materials. Coatings can be applied to pipes having diameters up to approximately 6″. Leak sealants of at least approximately 4 mils thick can cover insides of pipes, and can include novel mixtures of fillers and epoxy materials, and viscosity levels. A positive pressure can be maintained within the pipes during applications. Piping systems can be returned to service within approximately 96 hours.

This is a Divisional of U.S. patent application Ser. No. 13/683,332filed Nov. 21, 2012, which is a Divisional of U.S. patent applicationSer. No. 13/676,784 filed Nov. 14, 2012, now U.S. Pat. No. 8,795,768,which is a Divisional of U.S. patent application Ser. No. 12/813,873filed Jun. 11, 2010, now U.S. Pat. No. 8,343,579, which is a Divisionalof U.S. patent application Ser. No. 11/649,647 filed Jan. 4, 2007, nowissued as U.S. Pat. No. 7,858,149, which is a Continuation-In-Part ofU.S. patent application Ser. No. 11/246,825 filed Oct. 7, 2005, nowissued as U.S. Pat. No. 7,517,409, which is a Divisional of U.S. patentapplication Ser. No. 10/649,288 filed Aug. 27, 2003, now issued as U.S.Pat. No. 7,160,574 on Jan. 9, 2007, which claims the benefit of priorityto U.S. Provisional Patent Application 60/406,602 filed Aug. 28, 2002,all of which are incorporated by reference.

FIELD OF INVENTION

This invention relates to repairing leaks in pipes, and in particular tomethods, systems and apparatus for repairing leaks and providing barrierprotective coatings in a single operation to the interior walls of smalldiameter metal and plastic pressurized pipes such as pressurized drainlines, hot water lines, cold water lines, potable water lines, naturalgas lines, HVAC piping systems, and fire sprinkler system lines, and thelike, that are used in multi-unit residential buildings, officebuildings, commercial buildings, and single family homes, and the like.

BACKGROUND AND PRIOR ART

Large piping systems such as those used in commercial buildings,apartment buildings, condominiums, as well as homes and the like thathave a broad base of users commonly develop problems with their pipessuch as their water and plumbing pipes, and the like. Presently when afailure in a piping system occurs the repair method may involve a numberof separate applications. Those repair applications may involve aspecific repair to the area of failure such as replacing that section ofpipe or the use of a clamping devise and a gasket.

Traditional techniques to correct for the leak have included replacingsome or all of a building's pipes. In addition to the large expense forthe cost of the new pipes, additional problems with replacing the pipesinclude the immense labor and construction costs that must be incurredfor these projects.

Most piping systems are located behind finished walls or ceilings, underfloors, in concrete or underground. From a practical viewpoint simplygetting to the problem area of the pipe to make the repair can createthe largest problem. Getting to the pipe for making repairs can requiretearing up the building, cutting concrete and/or having to dig holesthrough floors, the foundation or the ground. These labor intensiverepair projects can include substantial demolition of a buildings wallsand floors to access the existing piping systems. For example, tearingout of the interior walls to access the pipes is an expected result ofthe demolition necessary to fix existing pipes.

There is usually substantial time-consuming costs for removing thedebris and old pipes from the worksite. With these projects both thecost of new pipes and the additional labor to install these pipes arerequired expenditures. Further, there are additional added costs for thematerials and labor to replumb these new pipes along with the necessarywall and floor repairs that must be made to clean up for the demolitioneffects. For example, getting at and fixing a pipe behind drywall is notcompleting the repair project. The drywall must also be repaired, andjust the drywall type repairs can be extremely costly. Additionalexpenses related to the repair or replacement of an existing pipingsystem will vary depending primarily on the location of the pipe, thebuilding finishes surrounding the pipe and the presence of hazardousmaterials such as asbestos encapsulating the pipe. Furthermore, theseprior known techniques for making piping repair take considerableamounts of time which results in lost revenue from tenants and occupantsof commercial type buildings since tenants cannot use the buildingsuntil these projects are completed.

Finally, the current pipe repair techniques are usually only temporary.Even after encountering the cost to repair the pipe, the cost andinconvenience of tearing up walls or grounds and if a revenue propertythe lost revenue associated with the repair or replacement, the new pipewill still be subject to the corrosive effects of fluids such as waterthat passes through the pipes.

Over the years many different attempts and techniques have been proposedfor cleaning water type pipes with chemical cleaning solutions. See forexample, U.S. Pat. No. 5,045,352 to Mueller; U.S. Pat. No. 5,800,629 toLudwig et al.; U.S. Pat. No. 5,915,395 to Smith; and U.S. Pat. No.6,345,632 to Ludwig et al. However, these systems generally require theuse of chemical solutions such as liquid acids, chlorine, and the like,that must be run through the pipes as a prerequisite prior to anycoating of the pipes.

Other systems have been proposed that use dry particulate materials as acleaning agent that is sprayed from mobile devices that travel throughor around the pipes. See for example, U.S. Pat. No. 4,314,427 to Stolz;and U.S. Pat. No. 5,085,016 to Rose. However, these traveling devicesgenerally require large diameter pipes to be operational and cannot beused inside of pipes that are less than approximately 6 inches indiameter, and would not be able to travel around narrow bends. Thus,these devices cannot be used in small diameter pipes found in potablewater piping systems that also have sharp and narrow bends.

Other repair type techniques for sealing and repairing pipes haveincluded, for example, U.S. Pat. No. 5,622,209 to Naf; U.S. Pat. No.4,505,613 to Koga; U.S. Pat. No. 4,311,409 to Stang; U.S. Pat. No.3,727,412 to Marx et al.; and U.S. Pat. No. 3,287,148 to Hilbush.

Hilbush '148 describes a process for sealing laid gas pipes by blowingin a foamed sealing emulsion. The foam settles on the internal wall andcondenses there. In the case of leaks, it tends to settle in largerquantities which makes this technique unsuitable for many applications.This method is expressly suited only to gas pipes; solid additions tothe sealing emulsion are neither taught nor made obvious.

Marx, '412 describes a repair process in which the portion of the pipewith the leak is sealed at the front and rear ends. A speciallystabilized emulsion is then pressed in which issues at the leak, isdestabilized there and coagulates so that the leak is sealed. Actualsolid sealing materials are not therefore pressed into the pipes and thevehicle is water, not gas.

Stang '409 describes the sealing of leaks in laid pipes by very finesubstances having a high capillary action. The very fine and difficultto use substance is arranged externally at the leak and is wateredthere. The capillary pressure thus obtained counteracts the deliverypressure of the medium flowing in the pipe. The very fine insulatingmaterial must be laid onto the conduit from the exterior, afterexcavation of the leak.

Koga '613 describes a process and an apparatus for the internal repairof laid pipes by means of “plastic mist” conveyed in a gas stream. It isunclear whether actual leaks are also sealed with it. More importantly,this process does not appear to be able to immediately produce theplastic mist necessary to work.

Naf '209 describes s process where a sealant is introduced with waterand is part of a water sealant mixture. The water sealant mixture fillsa pipe resulting in adding multiple steps to the process of filling,setting up a hydraulic recirculating system, draining and drying thepiping system. The water/sealant mixture may also flow from the leakingsection creating water damage to the immediate area.

None of the prior art techniques describe a process where a barriercoating and leaks are sealed with a barrier coating application combinedwith a leak sealing operation.

Thus, the need exists for solutions to the above problems whereproviding a barrier coating and sealing leaks is accomplished in pipingsystems in a single operation.

SUMMARY OF THE INVENTION

A primary objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks of pressurizedpipes in buildings without having to physically remove and replace thepipes, where the leaks are sealed and the barrier coating is applied ina single operation.

A secondary objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks, in a singleoperation in pipes by initially cleaning the interior walls of thepipes.

A third objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks, in a singleoperation in pipes by applying a corrosion protection barrier coating tothe interior walls of the pipes that provides a barrier coating andseals leaks in one operation.

A fourth objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks, in a singleoperation, in pipes in buildings in a cost effective and efficientmanner.

A fifth objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks, in a singleoperation, in pipes which is applicable to small diameter piping systemsfrom approximately ⅜″ to approximately 6″ in diameter in piping systemsmade of various materials such as galvanized steel, black steel, lead,brass, copper or other materials such as PVC, and composites includingplastics, as an alternative to pipe replacement or repair.

A sixth objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks in pipes, in asingle operation which is applied to pipes, “in place” or insituminimizing the need for opening up walls, floors ceilings, or grounds.

A seventh objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks in pipes, in asingle operation, which minimizes the disturbance of asbestos linedpiping or walls/ceilings that can also contain lead based paint or otherharmful materials.

An eighth objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks in pipes, in asingle operation, where once the existing piping system is restored witha durable epoxy barrier coating the common effects of corrosion fromwater passing through the pipes will be delayed if not stopped entirely.

A ninth objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks in pipes, in asingle operation, to clean out blockage where once the existing pipingsystem is restored, users will experience an increase in the flow ofwater, which reduces the energy cost to transport the water.Additionally, the barrier epoxy coating leak sealant being applied tothe interior walls of the pipes can create enhanced hydrauliccapabilities again giving greater flow with reduced energy costs.

A tenth objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks in pipes, in asingle operation, where customers benefit from the savings in timeassociated with the restoration of an existing piping system.

An eleventh objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation, where customers benefit from the economical savingsassociated with the restoration and in-place leak repair of an existingpiping system, since walls, ceilings, floors, and/or grounds do notalways need to be broken and/or cut through.

A twelfth objective of the invention is to provide methods, systems anddevices for repairing interior walls and sealing leaks in pipes, in asingle operation, where income producing properties experience savingsby remaining commercially usable, and any operational interference andinterruption of income-producing activities is minimized.

A thirteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation, where health benefits had previously accrued, as thewater to metal contact will be stopped by a barrier coating therebypreventing the leaching of metallic and potentially other harmfulproducts from the pipe into the water supply such as but not limited tolead from solder joints and from lead pipes, and any excess leaching ofcopper, iron and lead.

A fourteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation where the pipes are being restored and repaired,in-place, thus causing less demand for new metallic pipes, which is anon-renewable resource.

A fifteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation, using a less intrusive method of repair where thereis less building waste and a reduced demand on expensive landfills.

A sixteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation, where the process uses specially filtered air thatreduces possible impurities from entering the piping system during theprocess.

A seventeenth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation, where the equipment package is able to functionsafely, cleanly, and efficiently in high customer traffic areas.

An eighteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation where the equipment components are mobile andmaneuverable inside buildings and within the parameters typically foundin single-family homes, multi unit residential buildings and variouscommercial buildings.

A nineteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation, where the equipment components can operate quietly,within the strictest of noise requirements such as approximately seventyfour decibels and below when measured at a distance of approximatelyseveral feet away.

A twentieth objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation where the barrier coating leak sealant material forapplication in a variety of piping environments, and operatingparameters such as but not limited to a wide temperature range, at awide variety of airflows and air pressures, and the like.

A twenty first objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation where the barrier coating leak sealant material andthe process is functionally able to deliver turnaround of restoredpiping systems to service within approximately twenty four hours orless.

A twenty second objective of the invention is to provide methods,systems and devices for repairing interior walls and sealing leaks inpipes, in a single operation, where the barrier coating material isdesigned to operate safely under NSF (National Sanitation Foundation)Standard 61 criteria in domestic water systems, with adhesioncharacteristics within piping systems in excess of approximately 400PSI.

A twenty third objective of the invention is to provide methods, systemsand devices for repairing interior walls and sealing leaks in pipes, ina single operation where the barrier coating material is designed as along-term, long-lasting, durable solution to pipe corrosion, pipeerosion, pinhole leak repair and related water damage to piping systemswhere the barrier coating extends the life of the existing pipingsystem.

A twenty fourth objective of the invention is to provide methods,systems and devices for both cleaning and coating interiors and leaksealing, the interior of pipes having diameters of up to approximately 6inches using dry particulates, such as sand and grit, prior to coatingthe interior pipe walls.

A twenty fifth objective of the invention is to provide methods, systemsand devices for cleaning coating interiors and sealing leaks of pipeshaving diameters of up to approximately 6 inches in buildings, withouthaving to section off small sections of piping for cleaning coating andleak sealing applications.

A twenty sixth objective of the invention is to provide methods, systemsand devices for cleaning the interiors of an entire isolated pipingsystem in a building in a single pass run operation.

A twenty seventh objective of the invention is to provide methods,systems and devices for barrier coating and leak sealing the interiorsof an entire isolated piping system in a building in a single pass runoperation.

The novel method and system of pipe restoration prepares and protectssmall diameter piping systems such as those within the diameter range ofapproximately ⅜ of an inch to approximately six inches and can includestraight and bent sections of piping from the effects of watercorrosion, erosion and electrolysis and sealing leaks in-place, thusextending the life of small diameter piping systems. The barrier coatingused as part of the novel process method and system, can be used inpipes servicing potable water systems, meets the criteria established bythe National Sanitation Foundation (NSF) for products that come intocontact with potable water. The epoxy material also meets the applicablephysical criteria established by the American Water Works Association asa barrier coating. Application within buildings ranges fromsingle-family homes to smaller walk-up style apartments to multi-floorconcrete high-rise hotel/resort facilities and office towers, as well ashigh-rise apartment and condominium buildings and schools. The novelmethod process and system allows for barrier coating and leak repair, ina single operation to potable water lines, natural gas lines, HVACpiping systems, hot water lines, cold water lines, pressurized drainlines, and fire sprinkler systems.

The novel method of application of an epoxy barrier coating leak sealantis applied to pipes right within the walls eliminating the traditionaldestructive nature associated with a re-piping job. Typically 1 systemor section of pipe can be isolated at a time and the restoration of thesystem or section of pipe can be completed in less than one to four days(depending upon the building size and type of application) with waterrestored within approximately less than approximately 24 toapproximately 96 hours. For hotel and motel operators that means nothaving to take rooms off line for extended periods of time. Too, formost applications, there are no walls to cut, no large piles of waste,no dust and virtually no lost room revenue. Entire building pipingsystems can be cleaned within one run through pass of using theinvention. Likewise, an entire building piping system can be coated andleaks sealed within one single pass operation as well.

Once applied, the epoxy coating not only seals the leak but creates abarrier coating on the interior of the pipe in the same operation. Theapplication process and the properties of the epoxy coating ensure theinterior of the piping system is fully coated and leaks repaired. Epoxycoatings are characterized by their durability, strength, adhesion andchemical resistance, making them an ideal product for their applicationas a barrier coating and leak sealant on the inside of small diameterpiping systems.

The novel barrier coating provides protection and extended life to anexisting piping system that has been affected by erosion corrosioncaused from internal burrs, improper soldering, excessive turns, andexcessive water velocity in the piping system, electrolysis and “wear”on the pipe walls created by suspended solids. The epoxy barrier coatingwill create at least an approximately 4 mil covering to the inside ofthe piping system and will seal leaks spanning up to approximately 125mils.

There are primarily 3 types of metallic piping systems that are commonlyused in the plumbing industry—copper, steel and cast iron. New steelpipes are treated with various forms of barrier coatings to prevent orslow the effects of corrosion. The most common barrier coating used onsteel pipe is the application of a zinc based barrier coat commonlycalled galvanizing. New copper pipe has no barrier coating protectionand for years was thought to be corrosion resistant offering a lifetimetrouble free use as a piping system.

Under certain circumstances that involved a combination of factors ofwhich the chemistry of water and installation practices a naturaloccurring barrier coating would form on the inside of copper pipes whichwould act as a barrier coating, protecting the copper piping systemagainst the effects of corrosion from the water.

In recent history, due to changes in the way drinking water is beingtreated and changes in installation practices, the natural occurringbarrier coating on the inside of copper pipe is not being formed or ifit was formed is now being washed away. In either case without anadequate natural occurring barrier coating, the copper pipe is exposedto the effects of corrosion/erosion, which can result in premature agingand failure of the piping system, most commonly referred to as a pinholeleak.

With galvanized pipe the zinc coating wears away leaving the pipeexposed to the effects of the corrosive activity of the water. Thisresults in the pipe rusting and eventually failing.

The invention can also be used with piping systems having plastic pipes,PVC pipes, composite material, and the like.

The novel method and system of corrosion control by the application ofan epoxy barrier coating and sealant can be applied to existing pipingsystems in-place, in the same operation.

The invention includes novel methods and equipment for providing barriercoating corrosion and a repair method for sealing leaks for the interiorwalls of small diameter piping systems in the same operation. The novelprocess method and system of internal leak repair and corrosion controlincludes at least three basic steps: Air Drying a piping system to beserviced; profiling the piping system using an abrasive cleaning agent;and applying the barrier coating leak sealant to selected coatingthickness layers inside the pipes. The novel invention can also includetwo additional preliminary steps of: diagnosing problems with the pipingsystem to be serviced, and planning and setting up the barrier coatingleak repair project onsite. Finally, the novel invention can include afinal end step of evaluating the system after applying the barriercoating leak repair and re-assembling the piping system.

A novel method and process of applying a barrier coating leak sealant topipes to fix openings and cracks in the pipes, can include the steps ofmixing an epoxy material to form a barrier coating leak sealant having aviscosity range of approximately 1,200 cps to approximately 60,000 cpsat room temperature, applying the barrier coating leak sealant tointerior walls of the pipes without dismantling all of the pipingsystem, wherein the barrier coating leak sealant provides an interiorbarrier for protecting the interior walls of the pipes and sealing leakopenings up to approximately 125 mils in diameter, and restoring thepipes of the existing piping system to service is less thanapproximately ninety six hours. A more preferable viscosity range isbetween approximately 10,000 cps to approximately 60,000 cps.

The method and process can further include the step of mixing anadditional filler material with the barrier coating to further fill inthe leak openings. The filler can be additional epoxy material. Theadditional filler material can be selected from the group consisting of:glass flakes, glass fibers, epoxy fibers, mica, clay, silica, cork, andplastics.

Approximately 100 to approximately 200 milliliters of unfilled epoxy canbe used for pipes having a length of approximately 5 feet toapproximately 30 feet, where the pipes are approximately ½ inch indiameter.

Approximately 100 to approximately 300 milliliters of unfilled epoxy canbe used for pipes having a length of approximately 5 feet toapproximately 30 feet, where the pipes are approximately ¾ inch indiameter.

Approximately 100 to approximately 400 milliliters of unfilled epoxy canbe used for pipes having a length of approximately 5 feet toapproximately 30 feet, where the pipes are approximately 1 inch indiameter.

Approximately 100 to approximately 500 milliliters of unfilled epoxy canbe used for the pipes having a length of approximately 5 feet toapproximately 30 feet, where the pipes are approximately 1¼inch indiameter.

Approximately 100 to approximately 600 milliliters of unfilled epoxy canbe used for pipes having a length of approximately 5 feet toapproximately 30 feet, where the pipes are approximately 1½ inch indiameter.

Approximately 100 to approximately 700 milliliters of unfilled epoxy canbe used for pipes having a length of approximately 5 feet toapproximately 30 feet, where the pipes are approximately 2 inches indiameter.

The mixed epoxy having a viscosity of approximately 1200 toapproximately 5000 cps has at least approximately 25% fillers.

The mixed epoxy having a viscosity of approximately 5001 toapproximately 10000 cps has at least approximately 20% fillers.

The mixed epoxy having a viscosity of approximately 10001 toapproximately 15000 cps has at least approximately 15% fillers.

The mixed epoxy having a viscosity of approximately 15001 toapproximately 25000 cps has at least approximately 10% fillers.

The mixed epoxy having a viscosity of approximately 25001 toapproximately 60000 cps has at least approximately 5% fillers.

The method and process can further include the step of applying andmaintaining a positive pressure fluid, that can include air, throughoutthe pipes to set the barrier coating for a selected time of at leastseveral minutes, wherein the positive pressure fluid is at a pressurelevel of at least approximately 1.5 PSI.

Further objects and advantages of this invention will be apparent fromthe following detailed description of the presently preferredembodiments which are illustrated schematically in the accompanyingdrawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the general six steps that is an overview for applying thebarrier coating leak sealant.

FIGS. 2A, 2B, 2C and 2D shows a detailed process flowchart using thesteps of FIG. 1 for providing the barrier coating leak sealant.

FIG. 3 shows a flow chart of the set up of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before explaining the disclosed embodiments of the present invention indetail it is to be understood that the invention is not limited in itsapplication to the details of the particular arrangements shown sincethe invention is capable of other embodiments. Also, the terminologyused herein is for the purpose of description and not of limitation.

This is a Divisional of U.S. patent application Ser. No. 13/683,332filed Nov. 21, 2012, which is a Divisional of U.S. patent applicationSer. No. 13/676,784 filed Nov. 14, 2012, now U.S. Pat. No. 8,795,768,which is a Divisional of U.S. patent application Ser. No. 12/813,873filed Jun. 11, 2010, now U.S. Pat. No. 8,343,579, which is a Divisionalof U.S. patent application Ser. No. 11/649,647 filed Jan. 4, 2007, nowissued as U.S. Pat. No. 7,858,149, which is a Continuation-In-Part ofU.S. patent application Ser. No. 11/246,825 filed Oct. 7, 2005, nowissued as U.S. Pat. No. 7,517,409, which is a Divisional of U.S. patentapplication Ser. No. 10/649,288 filed Aug. 27, 2003, now issued as U.S.Pat. No. 7,160,574 on Jan. 9, 2007, which claims the benefit of priorityto U.S. Provisional Patent Application 60/406,602 filed Aug. 28, 2002,all of which are incorporated by reference.

FIG. 1 shows the general six steps for a project overview for applyingthe barrier coating leak sealant to an existing piping system, whichinclude step one, 10 program diagnosis, step two, 20 project planning,step three, 30 drying piping system, step four 40, profiling the pipingsystem, step five, 50 applying barrier coating leak sealant to theinterior walls of the pipes in the piping system, and final step six 60evaluation and return to operation of the piping system.

Step One—Problem Diagnosis 10

For step one, 10, several steps can be done to diagnose the problem witha piping system in a building, and can include:

-   -   (a) Interview onsite engineering staff, property mangers, owners        or other property representatives as to the nature of the        current problem with the piping system.    -   (b) Evaluation of local and on-site water chemistry being used        in the piping system for hardness and aggressive qualities.    -   (c) Engineering evaluation, if necessary, to determine extent of        present damage to the wall thickness of the piping and overall        integrity of the piping system.    -   (d) Additional on-site testing of piping system, if necessary,        identifying leaks or the nature or extent of leaking.    -   (e) Corrosion control, leak sealing proposal development for        client, including options for pipe and fitting replacement where        necessary.    -   After completion of step one, 10, the project planning and setup        step 20 can be started.        Step Two—Project Planning and Setup 20        For step two, 20, several steps can be followed for planning and        setup for restoring the integrity of the piping system in a        building, and can include:    -   (a) Complete contract development with client, after the        diagnosis contract has started.    -   (b) Commence project planning with site analysis crew, project        management team, and on-site engineering/maintenance staff.    -   (c) Plan delivery of the equipment and supplies to the worksite.    -   (d) Complete equipment and supply delivery to worksite.    -   (e) Commence and complete mechanical isolation of the piping        system.    -   (f) Commence and complete set up of hosing and equipment.        Step Three—Air Drying—Step 1 Method of Corrosion Control and        Leak Repair 30

For step three, 30, the piping system to be prepared for the coating bydrying the existing pipes, and can include:

-   -   (a) Piping systems are mapped.    -   (b) Isolations of piping systems or pipe sections are prepared        and completed.    -   (c) The isolated piping system to receive the barrier coating        leak sealant is adapted to be connected to the barrier coating        equipment.    -   (d) The isolated pipe section or system is drained of water.    -   (e) Using moisture and oil free, hot compressed air, a flushing        sequence is completed on the piping system to assure water is        removed.    -   (f) Piping system is then dried with heated, moisture and oil        free compressed air.    -   (g) Length of drying sequence is determined by pipe type,        diameter, length complexity, location and degree of corrosion        contained within the piping system, if any.    -   (h) Exiting debris is captured with use of an air filter vacuum,        drawing air, which is used simultaneously with compressor.    -   (i) Inspections are completed to assure a dry piping system        ready for the barrier coating and sealant.        Step Four—Piping System Profiling—Step 2 of Method of Corrosion        Control and Leak Sealant 40

For step four, 40, the piping system is to be profiled, and can include:

-   -   (a) Dried pipes can be profiled using an abrasive agent in        varying quantities and types. The abrasive medium can be        introduced into the piping system by the use of the moisture and        oil free heated compressed air using varying quantities of air        and varying air pressures. The amount of the abrading agent is        controlled by the use of a pressure generator.    -   (b) The simultaneous use of the air filter vacuum at the exit        end, drawing air to assist the compressor, reducing the effects        of friction loss in the piping system, enhancing the effects of        the sanding and debris removal.    -   (c) The abraded pipe, when viewed without magnification, must be        generally free of all visible oil, grease, dirt, mill scale, and        rust. Generally, evenly dispersed, very light shadows, streaks,        and discolorations caused by stains of mill scale, rust and old        coatings may remain on no more than approximately 33 percent of        the surface. Also, slight residues of rust and old coatings may        be left in the craters of pits if the original surface is        pitted.    -   (d) Pipe profiling is completed to ready the pipe for the        application of the barrier coating leak sealant material.    -   (e) Visual inspections can be made at connection points and        other random access areas of the piping system to assure proper        cleaning and profiling standards are achieved.    -   (f) An air flushing sequence is completed to the piping system        to remove any residuals left in the piping system from the        profiling stage.        Step Five—Corrosion Control Epoxy Sealing Leak Repair and        Protection of the Piping—Step 3 of the Method of Corrosion        Control and Leak Repair 50

For step five, 50, the piping system is barrier coated and leaks sealedand can include:

-   -   (a) Piping system can be heated with hot, pre-filtered, moisture        and oil free compressed air to an appropriate standard for an        epoxy coating application.    -   (b) Piping system can be checked for leaks.    -   (c) If leaks are identified or are suspect and the approximate        size determined the operator may choose to apply the coating        material without fillers, if the leak is determined to        be >approximately 30 mils in width the operator can decide to        add fillers to the coating material, prior to injection into the        piping system.    -   (d) Coating and leak sealing material can be prepared and        metered to manufacturer's specifications using a proportionator.    -   (e) The barrier coating leak sealant and fillers are placed into        the epoxy carrying tube or injection device.    -   (f) The coating and leak sealant material can be injected into        the piping system using hot, pre-filtered, moisture and oil free        compressed air at temperatures, air volume and pressure levels        to distribute the epoxy barrier coating leak sealant throughout        the pipe segment, in sufficient amounts to eliminate the water        to pipe contact in order to create an epoxy barrier coating on        the inside of the pipe and seal the leak in a single operation.        During this wetting out stage a vacuum filter maybe used in        conjunction with the compressor to assist the wetting out of the        coating material. At all times, a neutral or positive pressure        must be maintained on the inside of the pipe.    -   (g) The coating can be applied to achieve a coating of at least        approximately 4 mils and sealing leaks up to approximately 125        mils in size.    -   (h) Once the epoxy barrier coating leak sealant is injected and        the piping segment is wetted out warm, pre-filtered, moisture        and oil free compressed air can be applied to create a positive        pressure inside the pipe with a continuous positive pressure        maintained of at least approximately 1.5 P.S.I. over the        internal surface of the pipe to achieve the initial set of the        epoxy barrier coating sealant takes place. After initial set and        still maintaining positive pressure confirm that all valves and        pipe segments support appropriate air flow indicating clear        passage of the air through the pipe i.e.: no areas of blockage.        Allow the barrier coating leak sealant to cure to manufacturer's        standards.    -   Positive pressure can be maintained until the epoxy has reached        its “initial set.” The time depends on the epoxies pot life, the        application temperature of the epoxy and the maintenance        temperature and the actual film thickness of the epoxy, these        factors all come into play when getting the epoxy to its initial        set. For example, an epoxy having a 30 minute pot life, measured        at room temperature, will need a positive pressure for at least        approximately 30 minutes at no less then room temperature. Thus,        a positive pressure should be maintained to at least the        manufacturers specification of the epoxies pot life when        measured at room temperature or until initial set is achieved.        Step Six—System Evaluation and Re-Assembly 60

The final step six, 60 allows for restoring the piping system tooperation and can include:

-   -   (a) Remove all process application fittings.    -   (b) Examine pipe segments to assure appropriate coating        standards, check to ensure all leaks are sealed.    -   (c) Re-confirm that all valves and pipe segments support        appropriate air flow.    -   (d) Install original valves, fittings/fixtures, or any other        fittings/fixtures as specified by building owner representative.    -   (e) Reconnect water system, and water supply.    -   (f) Complete system checks, testing and evaluation of the        integrity of the piping system.    -   (g) Complete a water flush of system, according to        manufacturer's specifications.    -   (h) Evaluate water flow and quality.    -   (i) Document piping layout schedule, and complete pipe labeling.

FIGS. 2A, 2B, 2C and 2D show a detailed process flowchart using thesteps of FIG. 1 for providing the barrier coating leak sealant. Theseflow chart figures show a preferred method of applying a novel barriercoating leak sealant for the interior of small diameter piping systemsfollowing a specific breakdown of a preferred application of theinvention.

Components in FIG. 3 will now be identified as follows:

IDENTIFIER EQUIPMENT 100 395, 850, 1100, 1600 CFM Compressors Outfittedwith Aftercooler, Water separator, Fine Filter and Reheater (ifrequired) 200 Main Air Header and Distributor (Main Header) 300 FloorManifold (optional) 400 Sander 500 Pre-Filter 600 Dust Collector System(Air Filter Vacuum) 700 Portable Epoxy Metering and Dispensing Unit(Epoxy Mixer) 800 Epoxy Barrier Coating and Sealant 900 Epoxy CarryingTube - Injection Device

Referring to FIG. 3, components 100-900 can be located and used atdifferent locations in or around a building. The invention allows for anentire isolated building piping system to be cleaned in one single passthrough run without having to dismantle either the entire or multiplesections of the piping system. The piping system can include pipeshaving diameters of approximately ⅜ of an inch up to approximately 6inches in diameter with the piping including bends up to approximatelyninety degrees or more throughout the building. The invention allows foran entire isolated building piping system to have the interior surfacesof the pipes coated and leaks sealed in one single pass through runwithout having to dismantle either the entire or multiple parts of thepiping system. Each of the components will now be defined.

100 Air Compressor

The air compressors 100 can provide filtered and heated compressed air.The filtered and heated compressed air employed in various quantities isused, to dry the interior of the piping system, as the propellant todrive the abrasive material used in cleaning of the piping system and isused as the propellant in the application of the epoxy barrier coatingleak sealant and the drying of the epoxy barrier coating leak sealantonce it has been applied. The compressors 100 also provide compressedair used to propel ancillary air driven equipment.

200 Main Air Header and Distributor

An off the shelf main header and distributor 200 shown in FIG. 3 can beone Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo StreetBrea, Calif. 92821.

The Main Header 200 provides safe air management capability from the aircompressor for both regulated and unregulated air distribution (or anycombination thereof) to the various other equipment components and toboth the piping system risers and fixture outlets for a range of pipingconfigurations from a single family home to a multi-story building. Theair enters through the 2″ NPT inlet to service the pressure vessel. Themain header 200 can manage air capacities ranging to approximately 1600CFM and approximately 200 psi.

There are many novel parts and benefits with the Main Header andDistributor 200. The distributor is portable and is easy to move andmaneuver in tight working environments. Regulator Adjustment can easilyand quickly manage air capacities ranging to approximately 1600 CFM andapproximately 200 psi, and vary the operating airflows to each of theother ancillary equipment associated with the invention. The AirPressure Regulator and the Method of Distributing the air allows bothregulated and unregulated air management from the same equipment in auser-friendly, functional manner. The approximately 1″ Valving allowsaccommodation for both approximately 1″ hosing and with adapters, andhose sizes of less than approximately 1″″ can be used to meet a widevariety of air demand needs on a job site. The insulated cabinet,surrounding air works dampens noise associated with the movement of thecompressed air. The insulated cabinet helps retain heat of the pre-driedand heated compressed air, the pre-dried and heated compressed air beingan integral part of the invention. The insulated cabinet helps reducemoisture in the pressure vessel and air supply passing through it.Finally, the valving of the pressure vessel allows for delivery(separate or simultaneous) of regulated air to the side mounted airoutlet valves, the top mounted regulated air outlet valves as well asthe top mounted unregulated air outlet valves.

300 Floor Manifold

An on off-the-shelf floor manifold 300 can be one Manufactured By: M & HMachinery 45790 Airport Road, Chilliwack, BC, Canada

As part of the general air distribution system set up, the floormanifolds 300 can be pressure rated vessels designed to evenly andquietly distribute the compressed air to at least 5 other points ofconnection, typically being the connections to the piping system.Airflow from each connection at the manifold is controlled by the use ofindividual full port ball valves.

There are many novel parts and benefits to the Air Manifold 300. Theportability of manifold 300 allows for easy to move and maneuver intight working environments. The elevated legs provide a stable base forunit 300 as well as keep the hose end connections off the floor withsufficient clearance to permit the operator ease of access when havingto make the hose end connections. The threaded nipples placed atapproximately 45° angle allow for a more efficient use of space and lessrestriction and constriction of the airline hoses they are attached to.Multiple manifolds 300 can be attached to accommodate more than 5outlets. The manifolds can be modular and can be used as 1 unit or canbe attached to other units and used as more than 1.

400 Pressure Generator System-Sander

A pressure generator sander 400 that can be used with the invention canbe one Manufactured By: Media Blast & Abrasives, Inc. 591 W. ApolloStreet Brea, Calif. 92821.

The pressure generating sander system 400 can provide easy loading andcontrolled dispensing of a wide variety of abrasive medium in amounts upto approximately 1.3 US gallons at a time. The pressure generator sandercan include operational controls that allow the operator to easilycontrol the amount of air pressure and control the quantity of theabrasive medium to be dispersed in a single or multiple application. Theabrasive medium can be controlled in quantity and type and is introducedinto a moving air steam that is connected to a pipe or piping systemsthat are to be sand blasted clean by the abrasive medium. The sand canbe introduced by the pressure generator sander system 400 by beingconnected to and be located outside of the piping system depicted inFIG. 3. The novel application of the sander system 400 allows forcleaning small pipes having diameters of approximately ⅜″ up toapproximately 6″.

Table 1 shows a list of preferred dry particulate materials with theirhardness ratings from 1 to 10 (being the hardest), and grain shapes thatcan be used with the sand generator 400, and Table 2 shows a list ofpreferred dry particulate particle sieve sizes that can be used with theinvention.

TABLE 1 PARTICULATES Material Hardness Rating Grain Shape SiliconCarbide 10 Cubical Aluminium Oxide 9 Cubical Silica 5 Rounded Garnet 5Rounded

Table 1 shows the hardness and shapes of the typical types ofparticulates used in the cleaning and sanding process. Based on the MOHscale of hardness it is found that a 5 or higher hardness particulate beused in this process. A particulate such as silicon carbide isrecommended over a softer garnet particulate when used to clean andprofile harder metal pipes, such as steel, where the metal is a softer,such as copper it can be cleaned and profiled with a less hardparticulate such as garnet.

TABLE 2 PARTICULATE SIZE SIEVE SIZE OPENING U.S. Mesh Inches MicronsMillimeters 4 .187 4760 4.76 8 .0937 2380 2.38 16 .0469 1190 1.19 25.0280 710 .71 45 .0138 350 .35

Table 2 describes the various standards for measuring particulate size.In the cleaning and profiling stage an operator will decide to useparticulate of various sizes depending on the size of pipe, the type ofpiping material i.e. steel or copper and the degree and type of build upinside the pipe. In a copper pipe situation it is common to use a 24/25mesh size. When cleaning a heavily encrusted steel pipe an operatormight use a small particulate such as a 45 or 60 mesh to bore a holethrough the build up with our getting clogged up. As the opening insidethe pipe increases by cleaning, larger particulate sizes can be used.

There are many novel parts and benefits to the use of the PressureGenerator Sander System 400. The portability allows for easy to move andmaneuver in tight working environments. The sander 400 is able to accepta wide variety of abrasive media in a wide variety of media size.Variable air pressure controls in the sander 400 allows for managementof air pressures up to approximately 125 PSI. A mixing Valve adjustmentallows for setting, controlling and dispensing a wide variety ofabrasive media in limited and controlled quantities, allowing theoperator precise control over the amount of abrasive medium that can beintroduced into the air stream in a single or multiple applications. Thefiller lid incorporated as part of the cabinet and the pressure potallows the operator to load with ease, controlled amounts of theabrasive medium into the pressure pot. The pulse button can be utilizedto deliver a single sized quantity of the abrasive material into the airstream or can be operated to deliver a constant stream of abrasivematerial in to the air stream. All operator controls and hoseconnections can be centralized for ease of operator use.

500 Abrasive Reclaim Separator Module (Pre-Filter)

An off-the-shelf pre-filter that can be used with the invention can beone Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo StreetBrea, Calif. 92821

During the pipe profiling stage, the Pre-Filter 500 allows the filteringof air and debris from the piping system for more than two systems at atime through the 2—approximately 2″ NPT inlets. The cyclonechamber/separator captures the abrasive material and large debris fromthe piping system, the byproducts of the pipe profiling process. Thefine dust particles and air escape through the approximately 8″ air anddust outlet at the top of the machine and are carried to the dustcollection equipment 600, which filters, from the exhausting air, fineparticulates, that may not have been captured with the Pre-Filter 500.

There are many novel parts and benefits to the Pre-Filter 500. Thepre-filter has portability and is easy to move and maneuver in tightworking environments. The Dust Drawer with Removable Pan allows for easyclean out of the abrasive media and debris from the pipe. The CycloneChamber/Separator slows and traps the abrasive media and debris from thepiping system and air stream and prevents excess debris from enteringinto the filtration equipment. The 2—approximately 2″ NPT Inlets allowsa full range of air filtration from two separate riser or pipingsystems. Use of the approximately 8″ or greater flex tube as anexpansion chamber results in reducing the air pressure of the air as itleaves the Pre-filter 500 and reduces the potential for back pressure ofthe air as it departs the Pre-filter and enhances the operationalperformance of the air filter vacuum 600. When used in conjunction withthe air filter vacuum 600, the Pre-filter 500 provides a novel way ofseparating large debris from entering the final stage of the filtrationprocess. By filtering out the large debris with the Pre-filter 500 thispromotes a great efficiency of filtration of fine particles in the finalstages of filtration in the air filter vacuum 600. The approximately 8″air and dust outlet to the air filter vacuum 600 from the Pre-filter 500permits the compressed air to expand, slowing it in velocity before itenters the air filter vacuum 600, which enhances the operation of theair filter vacuum 600. Process cost savings are gained by the use of thePre-filter 500 by reducing the impact of filtering out the large amountsof debris at the Pre-filter stage prior to air entering the air filtervacuum 600. This provides for greater operating efficiencies at the airfilter vacuum 600 a reduction in energy usage and longer life and use ofthe actual fine air filters used in the air filter vacuum 600.

600 Dust Collection Filter—Air Filter Vacuum

An off-the-shelf example of an air filter vacuum 600 used with theinvention can be one Manufactured By: Media Blast & Abrasives, Inc. 591W. Apollo Street, Brea, Calif. 92821.

During the pipe profiling stage, the air filter vacuum or dust collector600 is the final stage of the air filtration process. The dust collector600 filters the passing air of fine dust and debris from the pipingsystem after the contaminated air first passes through the pre-filter500 (abrasive reclaim separator module).

During the drying stage the filter 600 can be used simultaneously withcompressor 100 aids in drawing air through the piping system. During thesanding or cleaning stage the filter 600 can be used with compressor 100the filter 600 assists by drawing air through the piping system. Thefilter 600 can be used simultaneously with the compressor 100 to createa pressure differential in the piping system which is used to reduce theeffects of friction loss and assists in a pulling action within the pipeduring the drying and sanding or cleaning stages as well as the coatingstage. The filter 600 can be capable of filtering air in volumes up toapproximately 1100 CFM.

There are many novel parts and benefits to the Air Filter 600. The airfilter has portability and is easy to move and maneuver in tight workingenvironments. The Dust Drawer with Removable Pan allows for easy cleanout of the abrasive media and debris from the filtration chamber. The 8″flexible duct permits the compressed air to expand and slow in velocityprior to entering the dust collector 600, enhancing efficiency. Thesliding air control exit vent permits use of a lower amperage motor onstart up. The reduced electrical draw enables the dust collector 600 tobe used on common household electrical currents while still being ableto maintain its capacity to filter up to approximately 1100 CFM of air.The air filter 600 keeps a flow of air running over the epoxy andenhancing its drying and curing characteristics. The dust collector 600creates a vacuum in the piping system, which is used as method ofchecking for airflow in the piping system.

The air filter 600 can be used simultaneously with compressor 100 toreduce the effects of friction loss, enhancing drying, sanding, epoxyinjection and drying.

700 Portable Epoxy Metering and Dispensing Unit

A metering and dispensing unit 700 used with the invention can be oneManufactured by: Lily Corporation, 240 South Broadway, Aurora, Ill.60505-4205.

The Portable Epoxy Metering and Dispensing Unit 700 can store up toapproximately 3 US gallons of each of A and B component of the two mixcomponent epoxy, and can dispense single shots up to approximately 14.76oz, in capacities up to approximately 75 US gallons per hour.

The unit 700 can be very mobile and can be used both indoors andoutdoors, and it can operate using a 15 Amp 110 AC electrical servicei.e.: regular household current and approximately 9 cubic feet (CFM) at90 to 130 pounds per square inch. The unit 700 requires only a singleoperator.

The epoxy 800 used with the unit 700 can be heated using this unit toits recommended temperature for application. The epoxy 800 can bemetered to control the amount of epoxy being dispensed.

There are many novel parts and benefits to the Epoxy Metering andDispensing Unit 700, which include portability and is easy to move andmaneuver in tight working environments. The heated and insulted cabinet,all epoxy transit hoses, valves and pumps can be heated within thecabinet. The Top filling pressurized tanks offers ease and access forrefilling. Epoxy 800 can be metered and dispensed accurately in singleshot or multiple shots having the dispensing capacity up toapproximately 14.76 ounces of material per shot, up to approximately 75gallons per hour.

The position of mixing head permits a single operator to fill theportable epoxy carrying tubes 900 in a single fast application. The driptray permits any epoxy overspill at the time of filling to be containedin the drip tray, containing the spill and reducing cleanup. The epoxycarrying tube hanger allows the operator to fill and temporarily storefilled epoxy tubes, ready for easy distribution. The pump and heatercombination allows for the epoxy to metered “on ratio” under a varietyof conditions such as changes in the viscosity of the epoxy componentswhich can differ due to temperature changes which effect the flow ratesof the epoxy 800 which can differ giving the operator an additionalcontrol on placement of the epoxy 800 by changing temperature and flowrates. Unit 700 provides greater operator control of the characteristicsof the epoxy 800 in the process.

800 Epoxy Barrier Coating Leak Sealant

A preferred epoxy barrier coating that can be used with the inventioncan be one Manufactured by: CJH, Inc. 2211 Navy Drive, Stockton, Calif.95206. The barrier coating product used in this process can be a 2-partthermo set resin with a base resin and a base-curing agent.

The preferred thermo set resin is mixed as a two-part epoxy that is usedin the invention. When mixed and applied, it forms a durable barriercoating leak sealant on pipe interior surfaces and other substrates. Thebarrier coating leak sealant provides a barrier coating that protectsthose coated surfaces from the effects caused by the corrosiveactivities associated with the chemistry of water and other reactivematerials on the metal and other substrates and seal leaks in the pipe.

The epoxy barrier coating sealant can be applied to create a protectivebarrier coating and leak sealant to pipes ranging in size approximately⅜″ to approximately 6″ and greater. The barrier coating can be appliedaround bends intersections, elbows, tee's, to pipes having differentdiameters and make up. The barrier coating leak sealant can be appliedto pipes in any position e.g.: vertical or horizontal and can be appliedas a protective coating leak sealant to metal and plastic type pipesused in fire sprinkler systems and natural gas systems. At least anapproximately 4 mils coating layer can be formed on the interior wallsof the pipes. The barrier coating leak sealant protects the existinginterior walls and can also stop leaks in existing pipes which havesmall openings and cracks, and the like, of up to approximately 125 milsin size.

Although the process of application described in this invention includesapplication of thermo set resins other types of thermo set resins can beused.

For example, other thermo set resins can be applied in the process, andcan vary depending upon viscosity, conditions for application includingtemperature, diameter of pipe, length of pipe, type of material pipecomprised of, application conditions, potable and non potable watercarrying pipes, and based on other conditions and parameters of thepiping system being cleaned, coated and leaks sealed by the invention.

Other thermo set type resins that can be used include but are notlimited to and can be one of many that can be obtained by numeroussuppliers such as but not limited to: Dow Chemical, Huntsmans AdvancesMaterial, formerly Ciba Giegy and Resolution Polymers, formerly ShellChemical.

A preferred viscosity range of the mixed as-applied epoxy used in thisprocess, before fillers are introduced, when measured at roomtemperature, 25° C., is in the range of approximately 1,200 centipoises(cps) to approximately 60,000 centipoises (cps), and preferably in anarrower range of 10,000 to 60,000 centipoises (cps.)

The preferred pot life, measured at room temperature is at leastapproximately 30 minutes.

Fillers used in the process preferably can contain a mixture of low andhigh aspect ratio particles, acicular shaped particles, and plate likeparticles.

Fillers preferably made of the same epoxy material that comprises thebarrier coating were used. Other materials may also be used include:glass flakes, glass fibers, epoxy fibers, mica, clay, silica, cork andplastics. The particle size and distribution of the fillers were notedas follows in Table 3

TABLE 3 US Sieve Size Inches Millimeters Microns #8 trace .0937 2.382380 #10 trace .0787 2.00 2000 #12  .6% .0661 1.68 1680 #16 21.6% .04691.19 1190 #20 41.2% .0331 .841 841 #30 21.6% .0234 .595 595 #40  6.0%.0165 .420 420

Table 3 shows the approximate breakdown of the size and % content of thesize of fillers contained in the filler mix. For example, about 41.2% ofthe filler passed through a #20 size sieve or were approximately 0.841millimeters in size. Only a trace amount of fillers passed through #8sieve and were larger in size i.e. 2.38 millimeters, when compared tothe size of the filler particles that passed through a #20 size sieve.The composition of mix of the various sizes of fillers were found toprovide a wide range of opportunity for the fillers to fill the holes orcracks of various sizes that can be found in the piping system, up toapproximately 125 mils in size.

Table 4 lists the amounts of epoxy needed for different length pipes anddifferent diameter pipes.

TABLE 4 UNFILLED EPOXY QUANTITY expressed in Milliliters Length PipeDimension (ft) ½″ ¾″ 1″ 1¼″ 1½″ 2″ 5 100 100 100 100 100 200 10 100 100200 200 200 300 15 100 200 200 300 300 400 20 200 200 300 300 400 500 25200 300 400 400 500 600 30 200 300 400 500 600 700

Referring to Table 5, a five foot length of piping having a ½ inchinside diameter would use approximately 100 milliliters of the novelunfilled epoxy.

A 30 foot long section of piping having an inside diameter ofapproximately 2 inches would use approximately 700 milliliters of thenovel unfilled epoxy.

TABLE 5 RATIO of Filler to Viscosity of Mixed EPOXY (cps) Mixed Epoxy byVolume  1,200-5,000 cps at least approximately 25% filler  5,001-10,000cps at least approximately 20% filler 10,001-15,000 cps at leastapproximately 15% filler 15,001-25,000 cps at least approximately 10%filler 25,001-60,000 cps at least approximately 5% filler

Table 5 lists the viscosity ranges in centipoises, and the amount offiller that is mixed into the unfilled epoxy. For example, an epoxyhaving a viscosity of approximately 1200 to 5000 cps would have at leastapproximately 25% fillers.

An epoxy having a viscosity of approximately 25,001 to approximately60,000 cps would have at least approximately 5% fillers.

Differences in viscosity were noted and primarily related to diameterand length of pipe. It was found that a lower viscose epoxy i.e. 1,200cps to 5,000 cps provided the operator the ability to coat and sealleaks over a longer distance in a small diameter pipe. For example, apipe of ½ inch or less in diameter over 100 feet in length. A moreviscose epoxy say in the range of 25,001 cps to 60,000 cps provided theoperator the ability to coat and seal leaks in larger diameter pipes sayfor example 2″ and greater in diameter and to seal small leaks withoutout same quantity of fillers as required with a lower viscose epoxy.

Although the novel invention can be applied to all types of metal pipessuch as but not limited to copper pipes, steel pipes, galvanized pipes,and cast iron pipes, the invention can be applied to pipes made of othermaterials such as but not limited to plastics, PVC (polyvinyl chloride),composite materials, polybutidylene, and the like. Additionally, smallcracks and holes in plastic type and metal pipes can also be fixed inplace by the barrier coating leak sealant.

Although the preferred applications for the invention are described withbuilding piping systems, the invention can have other applications suchas but not limited to include piping systems for swimming pools,underground pipes, in-slab piping systems, piping under driveways,various liquid transmission lines, tubes contained in heating andcooling units, tubing in radiators, radiant in floor heaters, chillersand heat exchange units, and the like.

While the invention has been described, disclosed, illustrated and shownin various terms of certain embodiments or modifications which it haspresumed in practice, the scope of the invention is not intended to be,nor should it be deemed to be, limited thereby and such othermodifications or embodiments as may be suggested by the teachings hereinare particularly reserved especially as they fall within the breadth andscope of the claims here appended.

We claim:
 1. A method for applying a barrier coating leak sealant tointernally seal leaks in a piping system, the method comprising thesteps of: blowing through a pipe compressed air that is charged withparticles of an abrasive substance to clean the inside of the pipe;introducing an epoxy barrier coating leak sealant into the pipe by acontinuous positive pressure of air in a single sealant stage; andcoating interior walls of the pipe in the single sealant stage bymaintaining at least approximately 1.5 P.S.I internal pressure overinterior walls of the pipe.
 2. The method as claimed in claim 1, whereinthe introducing step further comprises the step of mixing the epoxybarrier coating with fillers, selected from any one of the group ofepoxy, glass, plastic, foam parts, cork and clay.
 3. The method asclaimed in claim 1, further including the step of: drying interiorsurfaces of the pipe before the blowing step by introducingsubstantially moisture free and substantially oil free heated compressedair into one end of the pipe to remove moisture from the pipe.
 4. Themethod as claimed in claim 3, wherein the drying step includes the stepof: pulling the substantially moisture free and substantially oil freeheated compressed air by a vacuum through another end of the pipe toadditionally remove moisture from the pipe.
 5. The method of claim 1,wherein the introducing step includes the step of: providing the epoxybarrier coating leak sealant with a pot life of approximately 30 minuteswhen measured at room temperature.
 6. The method of claim 1, furtherincluding the step of: providing the epoxy barrier coating leak sealantadheres to the interior walls of the pipe in excess of approximately 400P.S.I.
 7. The method of claim 1, further including the step of:providing the epoxy barrier coating leak sealant adheres to the interiorwalls of the pipe in excess of approximately 2,500 P.S.I.
 8. A methodfor preparing insides of a pipe by cleaning, coating and sealing, themethod comprising the steps of: (a) cleaning the inside of the pipe; and(b) sealing the inside of the pipe in a single sealant stage with a leaksealant while maintaining a positive pressure of at least approximately1.5 P.S.I. in the pipe during the single sealant stage.
 9. The method ofclaim 8, further including the step of drying the inside of the pipebefore the cleaning step, the drying step includes the step ofintroducing substantially moisture free and substantially oil freeheated compressed air into one end of the pipe to remove moisture fromthe pipe.
 10. The method as claimed in claim 9, wherein the drying stepfurther includes the step of: pulling the substantially moisture freeand substantially oil free heated compressed air by a vacuum throughanother end of the pipe to additionally remove the moisture from thepipe.
 11. The method of claim 8, further comprising the step of:providing the leak sealant with a pot life of approximately 30 minuteswhen measured at room temperature.
 12. The method of claim 8, furthercomprising the step of: providing the leak sealant adheres to interiorwalls of the pipe in excess of approximately 400 P.S.I.
 13. The methodof claim 8, further comprising the step of: providing the leak sealantadheres to interior walls of the pipe in excess of approximately 2,500P.S.I.
 14. A method for preparing insides of pipes for repair, themethod comprising the following steps: (a) cleaning inside walls of apipe by introducing substantially moisture free and substantially oilfree heated compressed air into one end of the pipe to remove moisturefrom the pipe; and (b) repairing the inside walls of the pipe with aleak sealant pumped into the pipe at a continuous positive pressure bysealing interior walls of the pipe in a single sealant stage bymaintaining the continuous positive pressure in the single sealant stageat a pressure level of at least approximately 1.5 P.S.I.
 15. The methodof claim 14, further comprising the step of: providing the leak sealantwith a pot life of approximately 30 minutes when measured at roomtemperature.
 16. The method of claim 14, further comprising the step of:providing the leak sealant adheres to the interior walls of the pipe inexcess of approximately 400 P.S.I.
 17. The method of claim 14, furthercomprising the step of: providing the leak sealant adheres to theinterior walls of the pipe in excess of approximately 2,500 P.S.I. 18.The method of claim 14, further comprising the step of: providing theleak sealant with a pot life of approximately 30 minutes when measuredat room temperature.
 19. A method for applying a barrier coating leaksealant 1 to internally seal leaks in a pipe, the method comprising thesteps of: blowing through a pipe compressed air that is charged withparticles of an abrasive substance to clean the inside of the pipe; andintroducing an epoxy barrier coating leak sealant into the pipe bymaintaining a continuous positive pressure of at least approximately 1.5P.S.I. to coat interior walls of the pipe in a single sealant stage. 20.The method of claim 19, further comprising the step of: providing theleak sealant adheres to interior walls of the pipe in excess ofapproximately 400 P.S.I.
 21. The method of claim 19, further comprisingthe step of: providing the leak sealant adheres to interior walls of thepipe in excess of approximately 2,500 P.S.I.